CN108698308B - Method for producing shaped film - Google Patents

Method for producing shaped film Download PDF

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Publication number
CN108698308B
CN108698308B CN201780012405.9A CN201780012405A CN108698308B CN 108698308 B CN108698308 B CN 108698308B CN 201780012405 A CN201780012405 A CN 201780012405A CN 108698308 B CN108698308 B CN 108698308B
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China
Prior art keywords
thermoplastic resin
space
resin film
film
bending
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CN201780012405.9A
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Chinese (zh)
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CN108698308A (en
Inventor
神尾浩行
相矶良充
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Mitsui Chemicals Inc
Hopnic Laboratory Co Ltd
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Mitsui Chemicals Inc
Hopnic Laboratory Co Ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/10—Forming by pressure difference, e.g. vacuum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/0288—Controlling heating or curing of polymers during moulding, e.g. by measuring temperatures or properties of the polymer and regulating the process
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/008—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor without using a mould, e.g. ballooning
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/04—Combined thermoforming and prestretching, e.g. biaxial stretching
    • B29C51/06—Combined thermoforming and prestretching, e.g. biaxial stretching using pressure difference for prestretching
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/14—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor using multilayered preforms or sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/26—Component parts, details or accessories; Auxiliary operations
    • B29C51/30—Moulds
    • B29C51/36—Moulds specially adapted for vacuum forming, Manufacture thereof
    • B29C51/365—Porous moulds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/26—Component parts, details or accessories; Auxiliary operations
    • B29C51/42—Heating or cooling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/26—Component parts, details or accessories; Auxiliary operations
    • B29C51/42—Heating or cooling
    • B29C51/421—Heating or cooling of preforms, specially adapted for thermoforming
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/26—Component parts, details or accessories; Auxiliary operations
    • B29C51/42—Heating or cooling
    • B29C51/421—Heating or cooling of preforms, specially adapted for thermoforming
    • B29C51/424—Heating or cooling of preforms, specially adapted for thermoforming using a heated fluid
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/26—Component parts, details or accessories; Auxiliary operations
    • B29C51/42—Heating or cooling
    • B29C51/426—Producing specific thermal regimes during thermoforming to obtain particular properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/26—Component parts, details or accessories; Auxiliary operations
    • B29C51/46—Measuring, controlling or regulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/00009—Production of simple or compound lenses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/00634—Production of filters
    • B29D11/00644—Production of filters polarizing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/0073—Optical laminates
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00—Optical elements other than lenses
    • G02B5/30—Polarising elements
    • G02B5/3025—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state
    • G02B5/3033—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state in the form of a thin sheet or foil, e.g. Polaroid
    • G—PHYSICS
    • G02—OPTICS
    • G02C—SPECTACLES; SUNGLASSES OR GOGGLES INSOFAR AS THEY HAVE THE SAME FEATURES AS SPECTACLES; CONTACT LENSES
    • G02C7/00—Optical parts
    • G02C7/12—Polarisers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0805—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
    • B29C2035/0822—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation using IR radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2791/00—Shaping characteristics in general
    • B29C2791/004—Shaping under special conditions
    • B29C2791/006—Using vacuum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2791/00—Shaping characteristics in general
    • B29C2791/004—Shaping under special conditions
    • B29C2791/007—Using fluid under pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2027/00—Use of polyvinylhalogenides or derivatives thereof as moulding material
    • B29K2027/06—PVC, i.e. polyvinylchloride
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2029/00—Use of polyvinylalcohols, polyvinylethers, polyvinylaldehydes, polyvinylketones or polyvinylketals or derivatives thereof as moulding material
    • B29K2029/04—PVOH, i.e. polyvinyl alcohol
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2067/00—Use of polyesters or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2069/00—Use of PC, i.e. polycarbonates or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2077/00—Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2079/00—Use of polymers having nitrogen, with or without oxygen or carbon only, in the main chain, not provided for in groups B29K2061/00 - B29K2077/00, as moulding material
    • B29K2079/08—PI, i.e. polyimides or derivatives thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2011/00—Optical elements, e.g. lenses, prisms
    • B29L2011/0016—Lenses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/34—Layered products comprising a layer of synthetic resin comprising polyamides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • Ophthalmology & Optometry (AREA)
  • Manufacturing & Machinery (AREA)
  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Thermal Sciences (AREA)
  • Oral & Maxillofacial Surgery (AREA)
  • General Health & Medical Sciences (AREA)
  • Shaping Of Tube Ends By Bending Or Straightening (AREA)
  • Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
  • Laminated Bodies (AREA)

Abstract

The method for producing a shaped film of the present invention comprises the steps of: a step of disposing a thermoplastic resin film so that the space is divided into a 1 st space on one surface side and a 2 nd space on the other surface side of the film by the thermoplastic resin film; heating the thermoplastic resin film; a step of bending the thermoplastic resin film in the space by a pressure difference between the space 1 and the space 2; stopping the bending of the thermoplastic resin film in a state where at least a convexly curved surface of both surfaces of the film is exposed in the space; and a step of cooling the bent film.

Description

Method for producing shaped film
Technical Field
The present invention relates to a method for producing a shaped film.
Background
The plastic polarized lens can prevent the reflected light from transmitting. Thus, it has been used to: eyes are protected by blocking strong reflected light in outdoor places such as ski fields, fishing fields and the like; safety and the like are ensured by blocking reflected light from an oncoming vehicle while the vehicle is traveling. The plastic polarized lens is formed by laminating a plastic lens substrate and a polarized film. As the polarizing film, a shaped film is used.
Patent document 1 discloses a method for producing a polarizing film in which a gas is introduced into a member surrounding one surface of a film to pressurize the surface and press the other surface of the film against a heated mold surface. Also disclosed is a plastic article comprising the resulting polarized film.
Patent document 2 discloses a method for producing a polyimide film molded article, in which a polyimide film is shaped by adhering the polyimide film to the surface of a mold by utilizing the pressure difference between the space where one surface of the polyimide film is exposed and the space where the other surface of the polyimide film is exposed.
Patent document 3 discloses a method of hot forming by pressing a thermoplastic sheet against a mold using a low-pressure air flow.
Patent document 4 discloses a method for shaping a thermoplastic polyester under a predetermined temperature condition using a mold. Also disclosed is a plastic polarizing lens comprising the obtained polarizing film.
Patent document 5 discloses a method of bringing a wafer into contact with a mold having a surface with a predetermined shape and forming the wafer into a curved shape. Optical components comprising the resulting curved shaped wafers are also disclosed.
Patent document 6 discloses a die for pressure-air molding. Also disclosed is a method for shaping a film or sheet using the mold by the pressure of pressurized air.
Patent document 7 describes a method in which a preheated polarizing film having a planar shape is pressed against a convex surface of a lens base material with a spacer (pad) while pressing the polarizing film against the convex surface of the lens base material, and the film is adhered to the convex surface of the lens base material with a pressure-sensitive adhesive layer (fig. 2).
Patent document 8 describes a method in which a latex is spread on a convex surface of a lens base material by the film, the film is shaped, and the film is bonded to the convex surface of the lens base material by a latex layer formed on the convex surface (fig. 3A to 3C).
Documents of the prior art
Patent document
Patent document 1: japanese Kokai publication Hei-2003-533719
Patent document 2: japanese patent laid-open publication No. 2004-261961
Patent document 3: japanese patent laid-open publication No. 2005-289040
Patent document 4: international publication No. 2009/098886
Patent document 5: japanese laid-open patent publication No. 2012 and 5637
Patent document 6: japanese patent laid-open No. 2014-131858
Patent document 7: japanese Kohyo publication No. 2009-527783
Patent document 8: japanese Kokai publication 2008-529077
Disclosure of Invention
Problems to be solved by the invention
However, the techniques described in patent documents 1 to 8 have room for improvement in the following respects.
In the methods for shaping by pressing a film against the surface of a mold or by adhering a film to the surface of a mold as described in patent documents 1 to 6, there are cases where: when foreign matter is present on the mold surface, the shape of the foreign matter is transferred to the shaped film, and a desired surface shape cannot be obtained. Foreign matter may adhere to the surface of the shaped film, and contamination may occur. As described above, there is room for improvement in product yield.
In addition, this method requires that the mold surface be always kept clean, and maintenance and management of the mold are complicated, and there is room for improvement in the production efficiency of the product.
Further, as in patent document 7, in the method of forming by pressing a film with a spacer, there is room for improvement similar to the above.
In the technique described in patent document 8, since the latex is spread on the convex surface of the lens base material by the film, there are cases where: the film is itself stressed, affecting the optical properties of the film. Further, there are cases where: if the thickness of the latex layer is not uniform, a shaped film having a desired surface shape cannot be obtained. As described above, there is room for improvement in product yield.
Means for solving the problems
The present invention can be shown as follows.
[1] A method for producing a shaped film, comprising the steps of:
a step of disposing a thermoplastic resin film so that the space is divided into a 1 st space on one surface side and a 2 nd space on the other surface side of the film by the thermoplastic resin film;
heating the thermoplastic resin film;
a step of bending the thermoplastic resin film in the space by a pressure difference between the space 1 and the space 2;
stopping the bending of the thermoplastic resin film in a state where at least a convexly curved surface of both surfaces of the film is exposed in the space; and
and a step of cooling the bent film.
[2] The method for producing a shaped film according to [1], wherein the step of bending the thermoplastic resin film comprises:
and a step of pressing at least one of the 1 st space and the 2 nd space to bend the thermoplastic resin film into a space having a smaller pressure.
[3] The method for producing a shaped film according to [1], wherein the step of bending the film comprises:
and a step of reducing the pressure in at least one of the 1 st space and the 2 nd space to bend the thermoplastic resin film into a space having a smaller pressure.
[4] The method for producing a shaped film according to [1], wherein the step of bending the film comprises:
and a step of pressing one of the 1 st space and the 2 nd space and depressurizing the other space to bend the thermoplastic resin film into the depressurized space.
[5] The method for producing a shaped film according to [2] or [4], wherein the step of bending the thermoplastic resin film comprises:
and a step of loading a medium into one of the 1 st space and the 2 nd space and pressurizing the one space to bend the thermoplastic resin film into the other space.
[6] The method for producing a shaped film according to [2], wherein the step of bending the thermoplastic resin film comprises:
using a molding die disposed in the 1 st space or the 2 nd space and a medium supply mechanism for supplying a medium to a surface of the molding die facing the thermoplastic resin film,
and a step of pressing the thermoplastic resin film in the 1 st space or the 2 nd space with a medium supplied from the medium supply means between the molding die and the thermoplastic resin film, and bending the thermoplastic resin film by a pressure difference between the pressure in the other space and the pressure in the other space without contacting the surface of the molding die.
[7] The method for producing a shaped film according to [6], wherein the surface of the molding die facing the thermoplastic resin film is a convex surface or a concave surface having a substantially hemispherical shape.
[8] The method for producing an shaped film according to [6] or [7], wherein the molding die contains a porous body.
[9] The method for producing a shaped film according to [5], wherein the step of bending the thermoplastic resin film into the other space comprises:
and a step of bending the thermoplastic resin film into the other space at a temperature of 30 to 300 ℃ by filling the heated medium into the 1 st space or the 2 nd space and pressurizing the space.
[10] The method for producing a shaped film according to [5], wherein the step of bending the thermoplastic resin film comprises:
and controlling the amount of bending of the thermoplastic resin film based on the position of the thermoplastic resin film detected by the position sensor.
[11] The method for producing a shaped film according to any one of [1] to [10], comprising, before the step of cooling the bent film:
and a step of reheating the bent film.
[12] The method for producing a shaped film according to [11], wherein the reheating step is performed at a temperature of from a heating temperature in the heating step to a temperature of not more than Tm (melting point) of a resin constituting the thermoplastic resin film.
[13] The method for producing a shaped film according to any one of [1] to [12], wherein the step of disposing the thermoplastic resin film comprises:
a step of placing a thermoplastic resin film on the 1 st molding member having the 1 st space portion opened in one direction so as to cover the opening portion and fixing the thermoplastic resin film to the opening end portion,
the step of bending the thermoplastic resin film includes: and a step of bending the thermoplastic resin film by utilizing a pressure difference between the 1 st space in which one surface of the thermoplastic resin film is exposed and the 2 nd space in which the other surface of the thermoplastic resin film is exposed, without contacting the inner wall surface of the 1 st molding member.
[14] The method for producing a shaped film according to [13], wherein the thermoplastic resin film is covered with a 2 nd molding member having a 2 nd space portion opened in one direction at least on a back surface of a surface exposed in the 1 st space portion.
[15] The shaped film production method according to [13], wherein the thermoplastic resin film and the first molding member are provided in a surrounding member in a state where the thermoplastic resin film is fixed to an opening end of the first molding member 1 and the other surface of the thermoplastic resin film is exposed in the surrounding member,
the step of bending the thermoplastic resin film includes: and a step of bending the thermoplastic resin film by reducing the pressure of one of the inside of the surrounding member and the inside of the 1 st space portion while maintaining the other at a normal pressure.
[16] The shaped film production method according to [13], wherein the thermoplastic resin film and the first molding member are provided in a surrounding member in a state where the thermoplastic resin film is fixed to an opening end of the first molding member 1 and the other surface of the thermoplastic resin film is exposed in the surrounding member,
the step of bending the thermoplastic resin film includes: and a step of bending the thermoplastic resin film by pressurizing one of the inside of the surrounding member and the inside of the 1 st space while maintaining the other at a normal pressure.
[17] The shaped film production method according to [13], wherein the thermoplastic resin film and the first molding member are provided in a surrounding member in a state where the thermoplastic resin film is fixed to an opening end of the first molding member 1 and the other surface of the thermoplastic resin film is exposed in the surrounding member,
the step of bending the thermoplastic resin film includes: and a step of bending the thermoplastic resin film by pressurizing one of the inside of the surrounding member and the inside of the 1 st space and depressurizing the other.
[18] The method for producing a shaped film according to any one of [13] to [17], wherein the step of bending the thermoplastic resin film and the step of reheating the bent film are performed as continuous steps in a state where the thermoplastic resin film is placed on the first molding member 1.
[19] The method for producing an shaped film according to any one of [15] to [18], wherein the surrounding member is provided with:
a 1 st heating mechanism for heating the thermoplastic resin film or a 2 nd heating mechanism for heating the inside of the surrounding member, and
a pressurizing mechanism for pressurizing the inside of the surrounding member or the 1 st space of the 1 st molding member, or a depressurizing mechanism for depressurizing the inside of the surrounding member or the 1 st space of the 1 st molding member.
[20] The method for producing a shaped film according to [19], wherein the pressurizing mechanism comprises a medium introducing mechanism for introducing a medium into the surrounding member or the 1 st space of the 1 st molding member.
[21] The method for producing a shaped film according to [20], further comprising a 3 rd heating means for heating the medium.
[22] The method for producing an shaped film according to any one of [19] to [21], further comprising:
a position sensor capable of continuously measuring the position of the bent thermoplastic resin film, and
and a control unit for controlling the pressing unit based on the position of the thermoplastic resin film measured by the position sensor.
[23] The method for producing a shaped film according to any one of [1] to [22], wherein the thermoplastic resin film is selected from the group consisting of a polyvinyl alcohol film, a polyester film, a polyamide film, a polyimide film, a polyolefin film, a polyvinyl chloride film and a polycarbonate film.
[24] A method for producing a polarizing film, comprising the step of any one of [1] to [23 ].
[25] A method for manufacturing a polarized lens, comprising the steps of:
a step of disposing a thermoplastic resin film so that the space is divided into a 1 st space on one surface side and a 2 nd space on the other surface side of the film by the thermoplastic resin film;
heating the thermoplastic resin film;
a step of bending the thermoplastic resin film in the space by a pressure difference between the space 1 and the space 2;
stopping the bending of the thermoplastic resin film in a state where at least a convexly curved surface of both surfaces of the film is exposed in the space;
a step of cooling the bent film to obtain a polarizing film; and
and a step of laminating a lens base material on at least one surface of the polarizing film.
ADVANTAGEOUS EFFECTS OF INVENTION
The method for producing a shaped film according to the present invention can shape a thermoplastic resin film without contacting a mold or the like, and therefore, the surface is less likely to be damaged, and foreign matter is less likely to adhere to the surface, and therefore, a shaped film having a substantially spherical surface shape with a very smooth surface can be obtained by a simple method. That is, the production method of the present invention improves the yield of shaped films and products such as optical materials using the shaped films.
In addition, maintenance and management of the mold can be simplified, and thus production efficiency of the product can be improved.
Drawings
The above objects, and other objects, features and advantages will be further described with reference to the following preferred embodiments and accompanying drawings.
Fig. 1 is a cross-sectional view schematically showing a method for producing a shaped film according to the present embodiment.
Fig. 2 is a cross-sectional view schematically showing a method for producing a shaped film according to the present embodiment.
Fig. 3 is a cross-sectional view schematically showing a method for producing a shaped film according to the present embodiment.
Fig. 4 is a cross-sectional view schematically showing a method for producing a shaped film according to the present embodiment.
Fig. 5 is a cross-sectional view schematically showing a method for producing a shaped film according to the present embodiment.
Fig. 6 is a cross-sectional view schematically showing a method for producing a shaped film according to the present embodiment.
Detailed Description
The method for producing a shaped film of the present invention comprises the steps of:
a step of disposing a thermoplastic resin film so that the space is divided into a 1 st space on one surface side and a 2 nd space on the other surface side of the film by the thermoplastic resin film;
heating the thermoplastic resin film;
a step of bending the thermoplastic resin film in the space by a pressure difference between the space 1 and the space 2;
stopping the bending of the thermoplastic resin film in a state where at least a convexly curved surface of both surfaces of the film is exposed in the space; and
and a step of cooling the bent film.
Hereinafter, an embodiment of the method for producing a shaped film according to the present invention will be described with reference to the drawings as appropriate. In all the drawings, the same components are denoted by the same reference numerals, and the description thereof is omitted as appropriate.
The method for producing a shaped film according to the present embodiment includes the following steps.
Step a: the thermoplastic resin film 18 is disposed so that the space is divided into the 1 st space 16 on the one surface 18a side and the 2 nd space 22 on the other surface 18b side of the film by the thermoplastic resin film 18 (fig. 1 (a)).
And a step b: the thermoplastic resin film 18 is heated.
And c: the thermoplastic resin film 18 is bent into the 2 nd space 22 by the pressure difference between the 1 st space 16 and the 2 nd space 22 (fig. 1 (b)).
Step d: the bending of the thermoplastic resin film 18 is stopped in a state where the other surface 18b of the thermoplastic resin film 18 is exposed in the 2 nd space 22.
Step e: the bent thermoplastic resin film 18 is cooled.
Hereinafter, each step will be explained.
(Process a)
In step a, as shown in fig. 1(a), a thermoplastic resin film 18 is placed on the 1 st molding member 14 having the 1 st space 16 opened in one direction so as to cover the opening. One surface 18a of the thermoplastic resin film 18 is exposed in the 1 st space 16. Next, using the 2 nd molding member 24 having the 2 nd space 22 opened in one direction, the other surface 18b of the thermoplastic resin film 18 is covered with the 2 nd molding member 24 so that the other surface 18b is exposed in the 2 nd space 22.
The opening end of the 1 st molding member 14 and the opening end of the 2 nd molding member 24 can be fitted to each other, and the thermoplastic resin film 18 can be fixed between these opening ends.
The 1 st and 2 nd molding members 14 and 24 may be made of metal or the like.
The shape of the 1 st space 16 is not particularly limited as long as the thermoplastic resin film 18 is not in contact with the inner wall surface of the space 16 of the 1 st molding member 14 in the shaping step and the thermoplastic resin film 18 can be heated. The shape of the 2 nd space 22 is not particularly limited as long as the thermoplastic resin film 18 can be further heated by utilizing the pressure difference between the inside of the 1 st space 16 and the inside of the 2 nd space 22 in the shaping step.
The 1 st molding member 14 may be provided with a 1 st heating mechanism for heating the thermoplastic resin film 18, a 2 nd heating mechanism for heating the inside of the 1 st space 16, a conveying mechanism for loading a medium into the 1 st space 16 for pressurizing the inside of the 1 st space 16, a 3 rd heating mechanism for heating the medium, or a decompression mechanism for decompressing the inside of the 1 st space 16. May be constructed in such a manner that the heated medium can circulate in the 1 st space 16. The first molding member 14 may not be a closed system.
The 2 nd molding member 24 may be provided with a 1 st heating mechanism for heating the thermoplastic resin film 18, a 2 nd heating mechanism for heating the inside of the 2 nd space 22, a conveying mechanism for loading a medium into the 2 nd space 22 for pressurizing the inside of the 2 nd space 22, a 3 rd heating mechanism for heating the medium, or a decompression mechanism for decompressing the inside of the 2 nd space 22. May be constructed in such a manner that the heated medium can circulate in the 2 nd space 22. The 2 nd molding member 24 may not be a closed system.
The medium is not particularly limited as long as the thermoplastic resin film 18 can be heated and a pressure difference can be applied to the front and back surfaces of the film, and examples thereof include inert gases such as air and nitrogen, and liquids such as water vapor and water.
Examples of the 1 st heating means include an infrared irradiation device, a heat ray irradiation device, and an oven. The 2 nd heating means may be an oven or the like.
Examples of the thermoplastic resin film 18 include a polyvinyl alcohol film, a polyester film made of polyethylene terephthalate, polyethylene naphthalate, or the like, a polyamide film, a polyimide film, a polyolefin film, a polyvinyl chloride film, and a polycarbonate film. The thickness of the thermoplastic resin film 18 is suitably selected, although the preferred thickness varies depending on the application of the shaped film to be obtained. These thermoplastic resin films may contain dichroic dyes, light control pigments, specific wavelength cut pigments, dyes, ultraviolet absorbers, and the like.
(Process b)
Next, the thermoplastic resin film 18 is heated in a state where the thermoplastic resin film 18 is fixed by the opening end portion of the 1 st forming member 14 and the opening end portion of the 2 nd forming member 24.
The heating temperature varies depending on the presence or absence of the reheating step described later, the stretching state (presence or absence and magnification) and the material and thickness of the thermoplastic resin film 18, but in the case of polyester film formation by stretching treatment, the heating temperature is 30 to 300 ℃, preferably 100 to 200 ℃, and more preferably 120 to 180 ℃. The heating temperature of the thermoplastic resin film 18 can be confirmed by measuring the temperature of the medium in the space in which the film is exposed or the temperature of the surroundings around the film.
In order to heat the thermoplastic resin film 18, the following method may be mentioned: a method of heating by light, heat ray, or the like by a 1 st heating mechanism provided in the 1 st molding member 14 and/or the 2 nd molding member 24; the method includes heating the 1 st space 16 and/or the 2 nd space 22 by the 2 nd heating means provided in the 1 st molding member 14 and/or the 2 nd molding member 24. In the step c, the thermoplastic resin film 18 can be heated by using a heated medium.
The step b and the step c can be performed simultaneously by a method of circulating the heated medium in the 1 st space 16.
(Process c)
Next, the thermoplastic resin film 18 is bent in the space by the pressure difference between the 1 st space 16 and the 2 nd space 22. This step is performed while maintaining the temperature of step b or while heating.
In order to generate a pressure difference between the 1 st space 16 and the 2 nd space 22 as in this step, the following embodiments are given.
(i) The medium is charged into the 1 st space 16 while the 2 nd molding member 24 is opened to the atmosphere to maintain the atmosphere in the 2 nd space 22 at normal pressure. When the heated medium is circulated in the 1 st space 16, the step b and the step c may be performed simultaneously.
(ii) The medium is charged into the 1 st space 16 and the 2 nd space 22 so that the pressure in one space is higher than the pressure in the other space. When the heated medium is circulated in the 1 st space 16 and/or the 2 nd space 22, the step b and the step c may be performed simultaneously.
(iii) The medium is charged into the 1 st space 16 while the pressure in the 2 nd space 22 is reduced by the pressure reducing mechanism of the 2 nd molding member 24. When the heated medium is circulated in the 1 st space 16, the step b and the step c may be performed simultaneously.
(iv) The inside of the 2 nd space 22 is depressurized by the depressurizing mechanism of the 2 nd molding member 24, and the 1 st molding member 14 is opened to the atmosphere to maintain the inside of the 1 st space 16 at a normal pressure.
(v) The pressure in the 1 st space 16 is reduced by the pressure reducing mechanism of the 1 st molding member 14, and the pressure in the 2 nd space 22 is reduced by the pressure reducing mechanism of the 2 nd molding member 24 so that the pressure in one space is higher than the pressure in the other space.
The pressure in the 1 st space 16 when the pressure is applied varies depending on the material, temperature, film thickness and desired radius of curvature of the thermoplastic resin film 18, but is about 0.001 to 0.4MPa in the case of a stretched polyester film having a thickness of 100 to 200 μm. When the 1 st space 16 and the 2 nd space 22 are pressurized, the pressure difference can be appropriately set based on the material, temperature, film thickness, and desired radius of curvature of the thermoplastic resin film 18.
The radius of curvature of the thermoplastic resin film 18 in this step can be uniquely determined according to the relationship between the elastic force of the film and the applied pressure.
In the step c, the amount of deformation, pressure, and the like of the convex or concave surface of the curved shape formed in the thermoplastic resin film 18 can be checked to control the curvature of the thermoplastic resin film 18.
In the present embodiment, the step c may include a step of controlling the amount of bending of the thermoplastic resin film 18 based on a change in the position of the thermoplastic resin film 18 detected by a position sensor, not shown.
The position sensor may be located in either the 1 st space 16 or the 2 nd space 22. The position sensor is configured to detect a change in the position of the thermoplastic resin film 18 by a laser or the like and detect the amount of bending. Further, the control means can control the amount of bending of the thermoplastic resin film 18 by controlling the output of the pressurizing means or the depressurizing means based on the amount of bending. With this configuration, the amount of curvature of the thermoplastic resin film 18 can be accurately set, and the curvature can be set arbitrarily. The reference position (variation amount: 0) of the thermoplastic resin film 18 can be set to, for example, the position of the thermoplastic resin film 18 fixed between the 1 st molding member 14 and the 2 nd molding member 24.
The control means can grasp the change (the amount of bending) of the thermoplastic resin film 18 based on the position of the thermoplastic resin film 18 read by the position sensor, and control the output of the pressurizing means or the depressurizing means.
(Process d)
Then, the bending of the thermoplastic resin film 18 is stopped in a state where the other surface 18b of the thermoplastic resin film 18 is exposed in the 2 nd space 22. This allows the thermoplastic resin film 18 to be shaped without bringing the thermoplastic resin film 18 into contact with a molding die or the like.
In the step d, the thermoplastic resin film 18 can be bent to a desired shape by a position sensor, a control mechanism, or the like used in the step c, and the bending of the thermoplastic resin film 18 can be stopped without contacting the second forming member 24.
In the present embodiment, a step (heat-fixing step) of improving the thermal stability of the bent thermoplastic resin film 18 may be included.
The temperature at the time of reheating may be set to the same temperature as or higher than the heating temperature in step b, and preferably may be set to a temperature in the heating step to a temperature equal to or lower than the melting point of the resin constituting the thermoplastic resin film. In general, when heating is performed again, it is preferable to keep the heating for a certain period of time or shrink the heating.
By the reheating step, dimensional changes such as thermal shrinkage of the thermoplastic resin film 18 can be reduced. When the thermoplastic resin film 18 is made of a material that undergoes thermal shrinkage or the like, if the thermoplastic resin film is shrunk to some extent at a temperature equal to or higher than the use temperature, the effect of improving dimensional stability (suppressing the expected shrinkage at the use temperature to a small extent) can be obtained.
The step c of bending the thermoplastic resin film 18 and the step of forming the thermoplastic resin film 18 can be performed as a continuous step in a state where the thermoplastic resin film 18 is placed on the 1 st molding member, and a shaped film can be obtained by a simple method.
(Process e)
Next, the bent thermoplastic resin film 18 obtained in step d is cooled.
This step may be performed by another apparatus, but it is preferable to finish heating the thermoplastic resin film 18 and cool it while maintaining the pressurized state. For cooling, there are a method of lowering the temperature of the medium, a method of terminating heating by the heating means and returning to normal temperature, and the like.
By the present embodiment including such steps, a shaped film can be obtained.
[ use ]
The shaped film of the present embodiment can be used for various applications such as a polarizing substrate, a polarizing plate, a polarizing film, a specific wavelength cut film, a light control film, a reflective concave mirror, and a light collecting reflector for spectacles or sunglasses.
Hereinafter, a plastic polarizing lens will be described as an optical material using the shaped film of the present embodiment as a polarizing element.
[ Plastic polarizing lens ]
As the plastic polarized lens of the present embodiment, a plastic polarized lens including the shaped film (polarized film) obtained by the above-described manufacturing method and a plastic lens substrate laminated on at least one surface of the polarized film can be used. Alternatively, only a polarizing substrate or a polarizing plate including the shaped film obtained by the above-described production method may be used as the plastic polarizing lens.
As the polarizing film, various polarizing films such as a polyvinyl alcohol polarizing film containing iodine, a polyvinyl alcohol polarizing film containing a dichroic dye, a thermoplastic polyester polarizing film containing a dichroic dye, and the like can be used. In order to make the polyester polarizing film easier to mold than the polyvinyl alcohol polarizing film, the polyester polarizing film may contain water.
The thickness of the polarizing film is usually 1 to 500 μm, preferably 10 to 300 μm.
The polarizing film may have a single-layer structure, but may have a laminated structure in which sheets made of polycarbonate, triacetyl cellulose, polyamide, acrylic resin, polyethylene terephthalate, cyclic olefin copolymer, cyclic olefin polymer, or the like are laminated on both surfaces or one surface of the polarizing film.
In the case of a polarizing substrate or a polarizing plate, the above-mentioned sheet may be laminated on both surfaces or one surface of the polarizing substrate or the polarizing plate. The thickness of the polarizing substrate or the polarizing plate is usually 10 to 2000 μm, preferably 10 to 1000 μm.
The polarizing film may be subjected to 1 or 2 or more kinds of pretreatment selected from primer (coating) treatment, chemical treatment (treatment with a chemical solution such as a reactive gas, an acid, or an alkali), corona discharge treatment, plasma treatment, ultraviolet irradiation treatment, electron beam irradiation treatment, roughening treatment, flame treatment, etching treatment, washing treatment, and the like, and then used in order to improve adhesion to the lens base resin. Among such pretreatment, 1 or 2 or more selected from primer coating treatment, chemical treatment, corona discharge treatment, and plasma treatment are particularly preferable.
Examples of the resin constituting the lens base material include a thermosetting resin and a thermoplastic resin.
Examples of the thermosetting resin include a urethane resin, a thiourethane resin, an acrylic resin, an episulfide resin, and an allyl diglycol carbonate resin. The thermosetting resin may contain an internal mold release agent, an ultraviolet absorber, an antioxidant, a light stabilizer, an oil-soluble dye, a light-adjusting pigment, a specific wavelength-cutting pigment, a bluing agent, a chain extender, a crosslinking agent, a filler, and the like.
Examples of the thermoplastic resin include polycarbonate, polyamide, polymethyl methacrylate, polyester, polyolefin, polyurethane, polyether ketone, polyether sulfone, and polyvinyl chloride. They may be used in the form of an alloy obtained by mixing them.
Various function-imparting agents may be added to these thermoplastic resins. Examples of the function-imparting agent include an ultraviolet absorber, a heat stabilizer, an antioxidant, a light stabilizer, a flame retardant, a light control pigment, a specific wavelength cut pigment, a dye, a lubricant, a plasticizer, an antistatic agent, an antifogging agent, and an antibacterial agent.
In particular, in order to prevent the generation of foreign matter during melt kneading in the kneading step and the product production step, it is preferable to add a phosphorus-based heat stabilizer or a hindered phenol-based antioxidant.
If necessary, a release agent may be added. As the mold release agent, fatty acid esters can be suitably used. For example, monoglycerides of stearic acid, lower fatty acid esters such as stearyl stearate, higher fatty acid esters such as behenyl sebacate, and erythritol esters such as pentaerythritol tetrastearate can be used.
The embodiments of the present invention have been described above, but these are examples of the present invention, and various configurations other than the above can be adopted within a range not impairing the effects of the present invention.
For example, as shown in fig. 2, a thermoplastic resin film 18 is placed on the 1 st molding member 14 having the 1 st space portion 16 opened in one direction so as to cover the opening. Next, the thermoplastic resin film 18 is fixed to the opening end portion by the fixing member 20. As described above, the thermoplastic resin film 18 is disposed so as to be divided into the 1 st space portion 16 on the one surface 18a side and the space on the other surface 18b side of the thermoplastic resin film 18.
Then, as shown in fig. 2, the inside of the 1 st space portion 16 is pressurized to bend the thermoplastic resin film 18. The pressure in the 1 st space 16 may be reduced to bend the thermoplastic resin film 18 into the 1 st space 16.
In the heating step of the thermoplastic resin film 18, when the heating is performed by light or infrared rays, the heating may be performed directly from the other surface 18b side of the thermoplastic resin film 18. The step of bending the thermoplastic resin film 18 can be performed by pressurizing the inside of the 1 st space portion 16.
On the other hand, the method shown in fig. 2 may be performed in a surrounding member, not shown. A heating mechanism for heating the inside of the surrounding member, a pressurizing mechanism for pressurizing the inside of the surrounding member with gas or water vapor, a heating mechanism for heating the gas or water vapor, a pressurizing mechanism for pressurizing the inside of the 1 st space 16, and a depressurizing mechanism for depressurizing the inside of the 1 st space 16 may be provided in the surrounding member. The surrounding member may be configured to be openable to the atmosphere so that the inside of the surrounding member and the inside of the 1 st space 16 can be kept at normal pressure.
When the method shown in fig. 2 is performed inside the surrounding member, the following method can be employed for the step of bending the thermoplastic resin film 18.
(1) The thermoplastic resin film 18 is bent by pressurizing the inside of the 1 st space portion 16 while maintaining the inside of the surrounding member at normal pressure.
(2) The inside of the surrounding member and the 1 st space portion 16 are pressurized, so that the pressure in the 1 st space portion 16 is made higher than the pressure in the surrounding member, thereby bending the thermoplastic resin film 18.
(3) The pressure inside the surrounding member is reduced to pressurize the inside of the 1 st space portion 16, thereby bending the thermoplastic resin film 18.
(4) The pressure inside the surrounding member and the 1 st space 16 is reduced to make the pressure inside the 1 st space 16 higher than the pressure inside the surrounding member, thereby bending the thermoplastic resin film 18.
In fig. 2, the thermoplastic resin film 18 is bent in the direction of the second surface 18b, but the thermoplastic resin film 18 may be bent in the direction of the first surface 18a by reducing the pressure in the 1 st space portion 16.
When the thermoplastic resin film 18 is provided in the surrounding member, the following method can be employed for the step of bending the thermoplastic resin film.
(1) The thermoplastic resin film 18 is bent by reducing the pressure in the 1 st space portion 16 while maintaining the interior of the surrounding member at normal pressure.
(2) The thermoplastic resin film 18 is bent by pressurizing the inside of the surrounding member while maintaining the inside of the 1 st space portion 16 at normal pressure.
(3) The pressure inside the surrounding member is increased to reduce the pressure inside the 1 st space portion 16, thereby bending the thermoplastic resin film 18.
Further, as shown in fig. 3, a shaped film may be produced, and the following steps may be included.
Step a: the thermoplastic resin film 18 is disposed so that the space is divided into the 1 st space 16 on the one surface 18a side and the 2 nd space 22 on the other surface 18b side of the film by the thermoplastic resin film 18 (fig. 3 (a)).
And a step b: the thermoplastic resin film 18 is heated.
And c: the thermoplastic resin film 18 is bent into the 1 st space 16 by the pressure difference between the 1 st space 16 and the 2 nd space 22 without using a molding die (fig. 3 (b)).
Step d: the bending of the thermoplastic resin film 18 is stopped in a state where the one surface 18a of the thermoplastic resin film 18 is exposed in the 1 st space 16.
Step e: the bent thermoplastic resin film 18 is cooled.
The same configuration as that of the embodiment described in fig. 1 can be adopted, and the description of the same steps is omitted.
In the step c, the following method is used to generate a pressure difference between the 1 st space 16 and the 2 nd space 22.
(i) The medium is charged into the 2 nd space 22 while the 1 st molding member 14 is opened to the atmosphere to maintain the 1 st space 16 at a normal pressure. When the heated medium is circulated in the 2 nd space 22, the step b and the step c may be performed simultaneously.
(ii) The pressure in the 2 nd space 22 is increased by filling the 1 st space 16 and the 2 nd space 22 with the medium. When the heated medium is circulated in the 1 st space 16 and/or the 2 nd space 22, the step b and the step c may be performed simultaneously.
(iii) The medium is charged into the 2 nd space 22 while the 1 st space 16 is depressurized by the depressurizing mechanism of the 1 st molding member 14. When the heated medium is circulated in the 2 nd space 22, the step b and the step c may be performed simultaneously.
(iv) The inside of the 1 st space 16 is depressurized by the depressurizing mechanism of the 1 st molding member 14, and the 2 nd molding member 24 is opened to the atmosphere to maintain the inside of the 2 nd space 22 at a normal pressure.
(v) The pressure in the 1 st space 16 is reduced by the pressure reducing mechanism of the 1 st molding member 14, and the pressure in the 2 nd space 22 is reduced by the pressure reducing mechanism of the 2 nd molding member 24, so that the pressure in the 2 nd space 22 is increased.
In the method for producing a shaped film shown in fig. 3, a 1 st molding member 14 having a 1 st hemispherical space 16 shown in fig. 4 may be used. In the conventional art, the shaped film is produced by pressing the film 18 from the 2 nd space 22 side and simultaneously bonding the film 18 to the 1 st molding member 14 in the form as shown in fig. 4, but the shaped film can be produced without bringing the film 18 into contact with the 1 st molding member 14 by the present embodiment.
The step of bending the thermoplastic resin film 18 in the present embodiment can be controlled by measuring the amount of change using the volume of the medium for bending, for example.
In the step of bending the thermoplastic resin film 18 in the present embodiment, for example, the space on the side where bending is performed may be filled with a liquid (oil or the like) in advance, and the end point of bending may be controlled by the amount of the liquid pushed out by bending the thermoplastic resin film 18.
Further, as shown in fig. 5, a shaped film may be produced, and the following steps may be included.
Step a: the thermoplastic resin film 18 is disposed so that the space is divided into the 1 st space 16 on the one surface 18a side and the 2 nd space on the other surface 18b side of the film by the thermoplastic resin film 18 (fig. 5 (a)).
And a step b: the thermoplastic resin film 18 is heated.
And c: in the 1 st space 16, the thermoplastic resin film 18 is pressed by the medium 34 supplied between the forming die 32 and the thermoplastic resin film 18 in a state where the thermoplastic resin film 18 is not in contact with the forming die 32, and the thermoplastic resin film 18 is bent by a difference in pressure from the inside of the 2 nd space (fig. 5 (b)).
Step d: the bending of the thermoplastic resin film 18 is stopped. The other surface 18b of the thermoplastic resin film 18 is exposed in the 2 nd space.
Step e: the bent thermoplastic resin film 18 is cooled.
The same configuration as that of the embodiment described in fig. 1 can be adopted, and the description of the same steps is omitted.
Step a
As shown in fig. 5(a), a thermoplastic resin film 18 is placed on the 1 st molding member 14 having the 1 st space portion 16 opened in one direction so as to cover the opening. Next, the thermoplastic resin film 18 is fixed to the opening end portion by the fixing member 20. As described above, the thermoplastic resin film 18 is disposed so as to be divided into the 1 st space portion 16 on the one surface 18a side and the space on the other surface 18b side of the thermoplastic resin film 18.
A vertically movable molding die 32 is disposed in the 1 st molding member 14. The surface 32a of the molding die 32 is a convex surface having a substantially hemispherical shape. The molding die 32 is composed of a material capable of supplying a medium to the surface 32a of the molding die 32: a porous body having numerous pores; bundling the hollow tubes to stack the integrated articles in such a manner that the medium flows in one direction, for example, bundling tubular molded bodies to stack integrated hollow bodies; a structure using a plurality of plates, for example, a layered laminate configured by laminating a plurality of plates at intervals and allowing a medium to flow through gaps thereof; a structure in which a plurality of plates are combined into a lattice shape or a triangular shape; a fibrous body obtained by stacking fibrous objects; and so on.
Examples of the porous body include: sintering the metal; sintering the ceramic; a product obtained by aggregating products obtained by coating a binder on particulate inorganic substances (ceramics/metals); a foamed metal; foaming plastic; plastic granules obtained by aggregating the particles; organic polymer particles; a porous rubber; a product obtained by bundling hollow fibers and thereby stacking them; a hollow body in which tubular structures formed of metal, ceramic, plastic, rubber, or the like are bundled and stacked; a hollow body in which plate-like structures made of metal, ceramic, plastic, rubber, or the like are laminated so as to provide slits; and so on.
The molding die 32 includes a medium supply mechanism, not shown, and is capable of supplying a medium from the inside of the molding die 32 to the front surface 32 a. The medium is not particularly limited as long as the thermoplastic resin film 18 can be heated and a pressure difference can be applied to the front and back surfaces of the film, and examples thereof include inert gases such as air and nitrogen, and liquids such as water vapor and water.
Step c
When the thermoplastic resin film 18 is fixed to the opening end by the fixing member 20, the medium 34 is supplied from the medium supply mechanism to the surface 32a of the forming die 32 while the forming die 32 is moved in the direction of the thermoplastic resin film 18. Then, the molding die 32 is further raised, and the thermoplastic resin film 18 is bent by the pressing force of the medium 34 (fig. 5 (b)).
By supplying the medium 34 to the front surface 32a of the molding die 32, a layer of the medium 34 is formed between the molding die 32 and the thermoplastic resin film 18, and the surface shape of the molding die 32 can be transferred without the thermoplastic resin film 18 heated in the step b contacting the molding die 32.
That is, when the molding die 32 is moved toward the thermoplastic film 18 and gradually pressed against the film 18, the ejection pressure of the medium 34 ejected from the surface of the molding die 32, the resistance force in the molding die direction due to the elastic modulus at the heating temperature of the film 18, and the pressure applied in the direction opposite to the molding die 32 are balanced at a certain distance, and therefore, the shape of the molding die 32 can be transferred to the film 18 without the molding die 32 coming into contact with the film 18. As a result, the thermoplastic resin film can be bent. This can be performed by the same method as the method of forming a shape by contacting with a forming mold which is generally performed, but the formed film is not affected by the surface roughness of the forming mold because it does not contact with the forming mold.
The rising speed of the forming die 32, the temperature of the medium 34, the supply amount, the supply speed, and the like are adjusted so that the thermoplastic resin film 18 has a desired shape. In the present embodiment, the 2 nd space on the other surface 18b side of the thermoplastic resin film 18 is opened, and a large air pressure is applied to the other surface 18b, but as shown in fig. 1, a 2 nd molding member 24 having a 2 nd space 22 opened to one side may be used, and the other surface 18b may be covered with the 2 nd molding member 24 so that the other surface 18b of the thermoplastic resin film 18 is exposed in the 2 nd space 22. Thereby, the pressure in the 2 nd space 22 can also be adjusted.
As shown in fig. 6, a molding die 36 having a concave surface of a substantially hemispherical shape may be used.
In the embodiments of fig. 5 and 6, the entire apparatus may be used by being turned upside down, or may be used in a horizontal direction. In either case, the thermoplastic resin film can be shaped as described above.
As an optical material using the shaped film of the present embodiment as a polarizing element, a glass polarizing lens can be mentioned. The glass polarizing lens may include a glass polarizing lens comprising the shaped film (polarizing film) obtained by the above-described production method and a glass substrate laminated on at least one surface of the polarizing film.
Examples
The present invention will be described in more detail with reference to the following examples, but the present invention is not limited thereto.
[ example 1]
Production of the shaped film shown in FIG. 4
The 1 st molding member 14 and the 2 nd molding member 24 each having a laser-transmissive hole of 10mm diameter at the lower center were heated to 145 degrees (1 st heating means), and a polyethylene terephthalate polarizing film (140 μm in thickness) was horizontally placed between the members and fixed by fitting, and then the film distance was set to 0 by laser measurement (Keyence Corp CCD laser displacement meter LK-G150) and held for 120 seconds.
While maintaining the temperature, the inside of the 2 nd space 22 was pressurized at a pressure of 0.04MPa, and the polyethylene terephthalate polarizing film was expanded toward the 1 st space 16 side. Then, when the film distance was measured to be-5.6 mm by laser measurement, the film distance was maintained between-5.6 mm and-5.2 mm for 30 seconds while manually depressurizing (by opening to the atmosphere) and pressurizing the pressure in the 2 nd space 22.
Further, water was circulated through the member of the 1 st molding member 14, and while manually reducing the pressure in the 2 nd space 22 (by opening to the atmosphere) and increasing the pressure, the film distance was maintained between-5.6 mm and-5.2 mm for 60 seconds, and then the 1 st molding member 14 and the 2 nd molding member 24 were opened to obtain a curved film shaped to have a height of 5.4mm and a curvature radius of 130.4 mm.
The surface of the curved film was visually observed, and as a result, it was confirmed that no damage or foreign matter was present on the surface, and the surface had a very smooth surface. Further, the curved film was cut into two halves, and the cross-sectional shape was observed, and as a result, it was confirmed to have a substantially spherical shape.
[ example 2]
Production of the shaped film shown in FIG. 4
The 1 st molding member 14 and the 2 nd molding member 24 each having a laser-transmissive hole of 10mm diameter at the lower center were heated to 145 degrees (1 st heating means), and a polyethylene terephthalate polarizing film (140 μm in thickness) was horizontally placed between the members and fixed by fitting, and then the film distance was set to 0 by laser measurement (Keyence Corp CCD laser displacement meter LK-G150) and held for 120 seconds. While maintaining the temperature, the inside of the 2 nd space 22 was pressurized at a pressure of 0.04MPa, and the polyethylene terephthalate polarizing film was expanded toward the 1 st space 16 side. Next, when the film distance was measured to be-7.5 mm by laser measurement, the film distance was maintained between-7.5 mm and-6.5 mm for 30 seconds while manually depressurizing (by opening to the atmosphere) and pressurizing the pressure in the 2 nd space 22. Then, the pressure in the 2 nd space 22 was reduced by opening to the atmosphere, and when the film was contracted to a film distance of-5.4 mm, the film distance was maintained for 30 seconds between-5.6 mm and-5.2 mm while manually reducing the pressure in the 2 nd space 22 (by opening to the atmosphere) and increasing the pressure. Further, water was circulated through the member of the 1 st molding member 14, and while manually reducing the pressure in the 2 nd space 22 (by opening to the atmosphere) and increasing the pressure, the film distance was maintained between-5.6 mm and-5.2 mm for 60 seconds, and then the 1 st molding member 14 and the 2 nd molding member 24 were opened to obtain a curved film shaped to have a height of 5.4mm and a curvature radius of 130.4 mm.
The surface of the curved film was visually observed, and as a result, it was confirmed that no damage or foreign matter was present on the surface, and the surface had a very smooth surface. Further, the curved film was cut into two halves, and the cross-sectional shape was observed, and as a result, it was confirmed to have a substantially spherical shape.
[ example 3]
Method for producing polarizing lens using shaped film
Isophthalylmethylene diisocyanate 50.6 parts by weight, a mixture of 4, 8-dimercaptomethyl-1, 11-dimercapto3, 6, 9-trithioundecane and 4, 7-dimercaptomethyl-1, 11-dimercapto3, 6, 9-trithioundecane and 5, 7-dimercaptomethyl-1, 11-dimercapto3, 6, 9-trithioundecane 49.4 parts by weight, dibutyltin dichloride 0.01 part by weight as a curing accelerator, Zelec UN (registered trademark, manufactured by Stepan corporation) 0.1 part by weight as a mold release agent, and Seesorb 709(Shipro Kasei kassha ltd.) 0.05 part by weight as an ultraviolet absorber were stirred and dissolved, then, defoaming treatment was performed under reduced pressure, and immediately after preparation, the mixture was supplied as a monomer mixture for injection. The viscosity at 20 ℃ after stirring and dissolving for 1 hour was 30 mPas.
Next, the monomer mixture was passed through a 3 μm filter, filtered, and then injected through a tube (tube) into 2 voids partitioned by 2 glass molds constituting a mold for lens casting molding and the film shaped in example 1. The gap distance of the gap portion with the narrowest gap is about 0.5 mm. And (3) placing the cast mold for lens casting molding after injection and covering in a hot air circulating oven, heating from 25 ℃ to 108 ℃ after 12 hours, maintaining at 108 ℃ for 7 hours, slowly cooling, and taking the cast mold for lens casting molding out of the oven. The lens was released from the lens casting mold, and annealed at 110 ℃ for 2.5 hours to obtain a polarized lens.
[ example 4]
As the porous material, a porous aluminum material having an average pore diameter of 15 μm and a porosity of 15% was prepared, which had a substantially uniform thickness by cutting one surface thereof into a concave shape and cutting the other surface thereof into a convex shape. As in the mold 36 of fig. 6, the porous material is disposed in the space 16 in the mold of fig. 3 such that the concave surface faces the film. That is, in fig. 6, the second molding member 24 shown in fig. 3 is provided instead of the fixing member 20. Air (medium 34) was flowed from the back surface side to the concave surface of the porous material at a pressure of 0.02 MPa.
A uniaxially stretched PET film having a thickness of 140 μm was fitted between the No. 2 molding member 24 and the No. 1 molding member 14, the whole was heated at 145 ℃ for 120 seconds, 0.06MPa of air was applied to the No. 2 space 22, and after 60 seconds, the No. 2 molding member 24 and the No. 1 molding member 14 were cooled to 80 ℃. Then, the pressurization in the 1 st space 16 and the 2 nd space 22 is stopped, the fitting is opened, and the film subjected to the bending process is taken out.
The surface of the obtained film subjected to the bending process was visually observed, and it was confirmed that no damage or foreign matter was present on the surface and that the film had a very smooth surface. In addition, a lens can be produced in the same manner as in example 3.
The present application claims priority based on Japanese application No. 2016-032656, filed on 24/2/2016, the entire disclosure of which is incorporated herein.
The present invention can also adopt the following modes.
[1] A method for producing a shaped film, comprising the steps of:
a step of disposing a thermoplastic resin film so that the space is divided into a 1 st space on one surface side and a 2 nd space on the other surface side of the film by the thermoplastic resin film;
heating the thermoplastic resin film;
a step of bending the thermoplastic resin film in the space by a pressure difference between the space 1 and the space 2; and
and a step of cooling the bent film.
[2] The method for producing a shaped film according to [1], wherein the step of bending the thermoplastic resin film comprises:
and a step of pressing one of the 1 st space and the 2 nd space to bend the thermoplastic resin film into the other space.
[3] The method for producing a shaped film according to [1], wherein the step of bending the film comprises:
and a step of reducing the pressure in either the 1 st space or the 2 nd space to bend the thermoplastic resin film into the reduced pressure space.
[4] The method for producing a shaped film according to [1], wherein the step of bending the film comprises:
and a step of pressing one of the 1 st space and the 2 nd space and depressurizing the other space to bend the thermoplastic resin film into the depressurized space.
[5] The method for producing a shaped film according to [2] or [4], wherein the step of bending the thermoplastic resin film comprises:
and a step of loading a medium into one of the 1 st space and the 2 nd space and pressurizing the one space to bend the thermoplastic resin film into the other space.
[6] The method for producing a shaped film according to [5], wherein the step of bending the thermoplastic resin film into the other space comprises:
and a step of bending the thermoplastic resin film into the other space at a temperature of 30 to 300 ℃ by filling the heated medium into the 1 st space or the 2 nd space and pressurizing the space.
[7] The method for producing a shaped film according to [5], wherein the step of bending the thermoplastic resin film comprises:
and controlling the amount of bending of the thermoplastic resin film based on the position of the thermoplastic resin film detected by the position sensor.
[8] The method for producing a shaped film according to any one of [1] to [7], wherein the method comprises, before the step of cooling the bent film:
and a step of reheating the bent film.
[9] The method for producing a shaped film according to [8], wherein the reheating step is performed at a temperature of from a heating temperature in the heating step to a temperature of not more than Tm (melting point) of a resin constituting the thermoplastic resin film.
[10] The method for producing a shaped film according to any one of [1] to [9], wherein the step of disposing the thermoplastic resin film comprises: a step of placing a thermoplastic resin film on the 1 st molding member having the 1 st space portion opened in one direction so as to cover the opening portion and fixing the thermoplastic resin film to the opening end portion,
the step of bending the thermoplastic resin film includes: and a step of bending the thermoplastic resin film by utilizing a pressure difference between the 1 st space in which one surface of the thermoplastic resin film is exposed and the 2 nd space in which the other surface of the thermoplastic resin film is exposed, without contacting the inner wall surface of the 1 st molding member.
[11] The method for producing a shaped film according to [10], wherein the thermoplastic resin film is covered with a 2 nd molding member having a 2 nd space portion opened in one direction at least on a back surface of a surface exposed in the 1 st space portion.
[12] The shaped film production method according to [10], wherein the thermoplastic resin film and the first molding member 1 are provided in a surrounding member in a state where the thermoplastic resin film is fixed to an opening end of the first molding member 1 and the other surface of the thermoplastic resin film is exposed in the surrounding member,
the step of bending the thermoplastic resin film includes: and a step of bending the thermoplastic resin film by reducing the pressure of one of the inside of the surrounding member and the inside of the 1 st space portion while maintaining the other at a normal pressure.
[13] The shaped film production method according to [10], wherein the thermoplastic resin film and the first molding member 1 are provided in a surrounding member in a state where the thermoplastic resin film is fixed to an opening end of the first molding member 1 and the other surface of the thermoplastic resin film is exposed in the surrounding member,
the step of bending the thermoplastic resin film includes: and a step of bending the thermoplastic resin film by pressurizing one of the inside of the surrounding member and the inside of the 1 st space while maintaining the other at a normal pressure.
[14] The shaped film production method according to [10], wherein the thermoplastic resin film and the first molding member 1 are provided in a surrounding member in a state where the thermoplastic resin film is fixed to an opening end of the first molding member 1 and the other surface of the thermoplastic resin film is exposed in the surrounding member,
the step of bending the thermoplastic resin film includes: and a step of bending the thermoplastic resin film by pressurizing one of the inside of the surrounding member and the inside of the 1 st space and depressurizing the other.
[15] The method for producing a shaped film according to any one of [10] to [14], wherein the step of bending the thermoplastic resin film and the step of reheating the bent film are performed as continuous steps in a state where the thermoplastic resin film is placed on the first molding member 1.
[16] The method for producing an shaped film according to any one of [12] to [15], wherein the surrounding member is provided with:
a 1 st heating mechanism for heating the thermoplastic resin film or a 2 nd heating mechanism for heating the inside of the surrounding member, and
a pressurizing mechanism for pressurizing the inside of the surrounding member or the 1 st space of the 1 st molding member, or a depressurizing mechanism for depressurizing the inside of the surrounding member or the 1 st space of the 1 st molding member.
[17] The method for producing a shaped film according to [16], wherein the pressurizing mechanism comprises a medium introducing mechanism for introducing a medium into the surrounding member or the 1 st space of the 1 st molding member.
[18] The method for producing a shaped film according to [17], further comprising a 3 rd heating means for heating the medium.
[19] The method for producing an shaped film according to [17] or [18], further comprising:
a position sensor capable of continuously measuring the position of the bent thermoplastic resin film, and
and a control unit for controlling the pressing unit based on the position of the thermoplastic resin film measured by the position sensor.
[20] The method for producing a shaped film according to any one of [1] to [19], wherein the thermoplastic resin film is selected from the group consisting of a polyvinyl alcohol film, a polyester film, a polyamide film, a polyimide film, a polyolefin film, a polyvinyl chloride film and a polycarbonate film.
[21] A method for producing a polarizing film, comprising the step of any one of [1] to [20 ].
[22] A method for manufacturing a polarized lens, comprising the steps of:
a step of disposing a thermoplastic resin film so that the space is divided into a 1 st space on one surface side and a 2 nd space on the other surface side of the film by the thermoplastic resin film;
heating the thermoplastic resin film;
a step of bending the thermoplastic resin film in the space by a pressure difference between the space 1 and the space 2;
a step of cooling the bent film to obtain a polarizing film; and
and a step of laminating a lens base material on at least one surface of the polarizing film.

Claims (20)

1. A method for producing a shaped film, comprising the steps of:
sandwiching a thermoplastic resin film between a 1 st molding member and a 2 nd molding member, the 1 st molding member having a 1 st space opened in one direction, covering an opening of the 1 st space with the thermoplastic resin film, fixing the thermoplastic resin film between an opening end of the 1 st molding member and the 2 nd molding member, and dividing a space into the 1 st space on one surface side and a 2 nd space on the other surface side of the thermoplastic resin film;
heating the thermoplastic resin film;
a step of bending the thermoplastic resin film into a substantially spherical surface using an opening end portion of the 1 st molding member or the 2 nd member as a fulcrum while controlling a radius of curvature of the thermoplastic resin film by using a pressure difference between the inside of the 1 st space and the inside of the 2 nd space;
a step of ending the bending step in a state where a convex surface of the thermoplastic resin film that is bent is not in contact with a surface of the 1 st molding member or a surface of the 2 nd member; and
and a step of cooling the bent thermoplastic resin film.
2. The method for producing a shaped film according to claim 1, wherein the step of bending the thermoplastic resin film comprises:
and a step of pressing at least one of the 1 st space and the 2 nd space to bend the thermoplastic resin film into a space having a smaller pressure.
3. The method for producing a shaped film according to claim 1, wherein the step of bending the thermoplastic resin film comprises:
and a step of reducing the pressure in at least one of the 1 st space and the 2 nd space to bend the thermoplastic resin film in a space having a smaller pressure.
4. The method for producing a shaped film according to claim 1, wherein the step of bending the thermoplastic resin film comprises:
and a step of pressing one of the 1 st space and the 2 nd space and depressurizing the other space to bend the thermoplastic resin film into the depressurized space.
5. The method for producing a shaped film according to claim 2, wherein the step of bending the thermoplastic resin film comprises:
and a step of loading a medium into one of the 1 st space and the 2 nd space and pressurizing the one space to bend the thermoplastic resin film into the other space.
6. The method for producing a shaped film according to claim 2, wherein the step of bending the thermoplastic resin film comprises:
using a molding die disposed in the 1 st space or the 2 nd space and a medium supply mechanism that supplies a medium to a surface of the molding die that is opposed to the thermoplastic resin film,
and a step of pressing the thermoplastic resin film with a medium supplied from the medium supply mechanism between the molding die and the thermoplastic resin film in the 1 st space or the 2 nd space, and bending the thermoplastic resin film by a difference in pressure between the pressing force of the medium supply mechanism and the pressing force of the medium in the other space without contacting the surface of the molding die.
7. The method of producing a shaped film according to claim 6, wherein the surface of the molding die facing the thermoplastic resin film is a convex surface or a concave surface having a substantially hemispherical shape.
8. The method for producing an shaped film according to claim 6, wherein the molding die comprises a porous body.
9. The method for producing a shaped film according to claim 5, wherein the step of bending the thermoplastic resin film into the other space comprises:
and a step of bending the thermoplastic resin film into the other space at a temperature of 30 to 300 ℃ by filling the heated medium into the 1 st space or the 2 nd space and pressurizing the space.
10. The method for producing a shaped film according to claim 5, wherein the step of bending the thermoplastic resin film into the other space comprises:
and controlling the amount of bending of the thermoplastic resin film based on the position of the thermoplastic resin film detected by the position sensor.
11. The method for producing a shaped film according to claim 1, wherein the method comprises, after stopping the step of bending the thermoplastic resin film and before the step of cooling the bent thermoplastic resin film:
and a reheating step of reheating the bent thermoplastic resin film.
12. The method for producing a shaped film according to claim 11, wherein the reheating step is performed at a temperature of from a heating temperature in the heating step to a melting point Tm of a resin constituting the thermoplastic resin film or less.
13. The method for producing a shaped film according to claim 11, wherein the step of bending the thermoplastic resin film and the step of reheating the bent thermoplastic resin film are performed as continuous steps in a state where the thermoplastic resin film is placed on the 1 st molding member and the thermoplastic resin film is fixed between the opening end of the 1 st molding member and the 2 nd member.
14. The method for producing an shaped film according to claim 1, wherein the thermoplastic resin film is selected from the group consisting of a polyvinyl alcohol film, a polyester film, a polyamide film, a polyimide film, a polyolefin film, a polyvinyl chloride film, and a polycarbonate film.
15. The method for producing a shaped film according to claim 1, wherein,
the step of bending the thermoplastic resin film stops the bending in a state where a portion of the thermoplastic resin film not in contact with the 1 st molding member and the 2 nd molding member does not come in contact with the 1 st molding member and the 2 nd molding member before the bending is started.
16. The method for producing a shaped film according to claim 1, wherein,
the shape of the 1 st molding member and the 2 nd member is not changed during the bending of the thermoplastic resin film.
17. The method for producing a shaped film according to claim 1, wherein,
the 2 nd member is a 2 nd molding member having a 2 nd space opened in one direction,
in the step of fixing the thermoplastic resin film between the opening end of the 1 st molding member and the 2 nd molding member, the thermoplastic resin film is sandwiched between the 1 st molding member and the 2 nd molding member, the opening of the 1 st space and the opening of the 2 nd space are covered with the thermoplastic resin film, and the thermoplastic resin film is fixed between the opening ends of the 1 st molding member and the 2 nd molding member,
the thermoplastic resin film that has been bent is convex toward the 1 st space,
the depth of the 1 st space from the opening toward the bottom is deeper than the depth of the 2 nd space from the opening toward the bottom.
18. The method for producing a shaped film according to claim 1, wherein,
in the step of bending the thermoplastic resin film, a pressing force by a solid is not applied to a portion of the thermoplastic resin film that does not contact the 1 st molding member and the 2 nd member before the bending is started.
19. A method for producing a polarizing film, comprising the step of any one of claims 1 to 18, wherein the shaped film produced by the method for producing a shaped film of any one of claims 1 to 18 is used as the polarizing film.
20. A method for manufacturing a polarized lens, comprising the steps of:
sandwiching a thermoplastic resin film between a 1 st molding member and a 2 nd molding member, the 1 st molding member having a 1 st space opened in one direction, covering an opening of the 1 st space with the thermoplastic resin film, fixing the thermoplastic resin film between an opening end of the 1 st molding member and the 2 nd molding member, and dividing a space into the 1 st space on one surface side and a 2 nd space on the other surface side of the thermoplastic resin film;
heating the thermoplastic resin film;
a step of bending the thermoplastic resin film into a substantially spherical surface using an opening end portion of the 1 st molding member or the 2 nd member as a fulcrum while controlling a radius of curvature of the thermoplastic resin film by using a pressure difference between the inside of the 1 st space and the inside of the 2 nd space;
a step of ending the bending step in a state where a convex surface of the thermoplastic resin film that is bent is not in contact with a surface of the 1 st molding member or a surface of the 2 nd member;
a step of cooling the bent thermoplastic resin film to obtain a polarizing film; and
and a step of laminating a lens base material on at least one surface of the polarizing film.
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US11524443B2 (en) 2022-12-13
US20190061226A1 (en) 2019-02-28

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